JP2013156373A - Reflection screen manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a reflection screen capable of displaying an excellent video with high contrast and allowing easy manufacture.SOLUTION: A reflection screen 10 comprises: a lens layer 13 having a lens surface 132 and a non-lens surface 133 and having a Fresnel lens shape in which a plurality of unit lenses 131 serving as a convex lens are aligned at a back side; and a reflective layer 12 formed on at least part of the lens surface 132. The manufacturing method of the reflection screen 10 comprises: a lens layer formation step of forming the lens layer 13 having the Fresnel lens shape in which the plurality of unit lenses 131 are aligned on one surface; a reflective layer formation step of forming a reflective layer 12A on the lens surface 132 and the non-lens surface 133 by vapor deposition; and a reflective layer removal step of removing a reflective layer 12A formed at least on the non-lens surface 133.

Description

  The present invention relates to a method of manufacturing a reflective screen that reflects and displays projected image light.

In recent years, as a video source for projecting an image on a reflective screen, a short focus type video projection device (projector) that projects a video light at a relatively large incident angle from a close distance to realize a large screen display has been widely used. Yes. Such a short focal point type image projection apparatus can project on the reflection screen from above or below at a larger incident angle than a conventional image source, and saves space in an image display system using the reflection screen. Etc.
In order to satisfactorily display the image light projected by such a short focus type image projection device, the surface of the lens layer having a linear Fresnel lens shape or a circular Fresnel lens shape formed by arranging a plurality of unit lenses is used. Various reflective screens and the like on which a reflective layer is formed have been developed (for example, Patent Documents 1 and 2).

JP-A-8-29875 JP 2008-76523 A

  In the reflection screen as described above, when a reflection layer is also formed on a non-lens surface that does not contribute to the reflection of image light, a non-lens surface is formed when unnecessary external light such as illumination light enters the reflection screen. There is a problem that the image is reflected by a reflection layer formed in the same manner and reaches the observer side, and the contrast of the image is lowered.

Therefore, in order to improve the contrast, it is required to form a reflective layer on the lens surface that contributes to the reflection of the image light and not to form a reflection layer in a region that does not contribute to the reflection of the image light. However, since the unit lens is very small, it is difficult to form such a reflective layer.
The above-mentioned Patent Documents 1 and 2 do not disclose a method for forming a reflective layer only on a lens surface that contributes to the reflection of video light.

  The subject of this invention is providing the manufacturing method of the reflective screen which can display a favorable image with high contrast and can be manufactured easily.

The present invention solves the above problems by the following means. In addition, in order to make an understanding easy, although the code | symbol corresponding to embodiment of this invention is attached | subjected and demonstrated, it is not limited to this.
The invention of claim 1 includes a lens layer (13) having a Fresnel lens shape in which a plurality of unit lenses (131) having a lens surface (132) and a non-lens surface (133) and convex on the back side are arranged. And a reflective layer (12) formed on at least a part of the lens surface, and a method of manufacturing a reflective screen (10) for reflecting the image light projected from the image source (LS) and displaying it for observation A lens layer forming step of forming the lens layer having a Fresnel lens shape in which a plurality of unit lenses are arranged on one surface, and a reflective layer (12A, 22A) on the lens surface and the non-lens surface. A reflective screen manufacturing method comprising: a reflective layer forming step to be formed; and a reflective layer removing step of removing at least the reflective layer formed on the non-lens surface.
According to a second aspect of the present invention, in the reflective screen manufacturing method according to the first aspect, in the reflective layer removing step, at least the reflective layer (12A, 22A) formed on the non-lens surface (133) is removed by etching. A method of manufacturing a reflective screen.
A third aspect of the present invention is the method for manufacturing a reflective screen according to the second aspect, wherein the etching used in the step of removing the reflective layer is wet etching.
According to a fourth aspect of the present invention, in the reflective screen manufacturing method according to any one of the first to third aspects, the reflective layer is formed on the non-lens surface (133) in the reflective layer forming step. The thickness of (12A, 22A) is a manufacturing method of a reflective screen characterized in that it is thinner than the thickness of the reflective layer formed on the lens surface (132).
According to a fifth aspect of the present invention, in the reflective screen manufacturing method according to any one of the first to fourth aspects, in the reflective layer removing step, the reflective layer formed on the non-lens surface (133). (22A) and a method of manufacturing a reflective screen, wherein the reflective layer formed in the non-reflective region (132b) that does not contribute to the reflection of the image light on the lens surface (132) is removed.

  According to the present invention, a reflective screen capable of displaying a good image with high contrast can be easily manufactured.

It is a figure explaining video display system 1 of an embodiment. It is a figure explaining the layer structure of the reflective screen 10 of embodiment. It is a figure explaining the lens layer 13 of embodiment. It is a figure explaining the manufacturing method of reflective screen 10 of an embodiment. It is a figure which shows the reflection layer 22 of another embodiment.

Embodiments of the present invention will be described below with reference to the drawings. In addition, each figure shown below including FIG. 1 is the figure shown typically, and the magnitude | size and shape of each part are exaggerated suitably for easy understanding.
In addition, the terms “plate”, “sheet”, “film” and the like are used, but these are generally used in the order of thickness, “plate”, “sheet”, “film”. I am using it. However, such proper use has no technical meaning and can be replaced as appropriate.
Furthermore, numerical values such as dimensions and material names of each member described in the present specification are examples of the embodiment, and the present invention is not limited thereto, and may be appropriately selected and used.

(Embodiment)
FIG. 1 is a diagram illustrating a video display system 1 according to the present embodiment. FIG. 1A is a perspective view of the video display system 1, and FIG. 1B is a side view of the video display system 1.
The video display system 1 includes a reflective screen 10, a video source LS, and the like. The video display system 1 according to the present embodiment is a general video display system in which video light L projected from a video source LS is reflected by a reflective screen 10 and a video is displayed on the screen.
The video display system 1 is not limited to this, and may be, for example, a front projection television system that projects video light from the video source LS, or an input on the observation screen of the reflective screen 10, the video source LS, and the reflective screen. An interactive board system including a position detection unit for detecting the position of the unit and a personal computer may be used.

The video source LS is a device that projects the video light L onto the reflective screen 10, and a general-purpose short focus projector or the like can be used. This image source LS is in the center in the left-right direction of the reflection screen 10 when the screen of the reflection screen 10 is viewed from the normal direction (normal direction of the screen surface) in the use state. It is arranged at a position below the screen (display area).
Here, the screen surface indicates a surface in the planar direction of the reflection screen when viewed as the entire reflection screen.
The video source LS can project the video light L from a position where the distance from the reflective screen 10 in a direction orthogonal to the screen of the reflective screen 10 (thickness direction of the reflective screen 10) is much closer than that of a conventional general-purpose projector. . That is, the image source LS has a shorter projection distance to the reflection screen 10 and a larger incident angle of the image light L with respect to the reflection screen 10 than a conventional general-purpose projector.

The reflection screen 10 is a screen that displays the image by reflecting the image light L projected by the image source LS toward the observer O side. In the use state, the observation screen of the reflection screen 10 has a substantially rectangular shape with the long side direction being the left-right direction of the screen when viewed from the observer O side.
In the following description, unless otherwise specified, the screen vertical direction, screen horizontal direction, and thickness direction are the screen vertical direction (vertical direction) and screen horizontal direction (horizontal direction) when the reflective screen 10 is used. The thickness direction (depth direction) is assumed.

The reflective screen 10 is provided with a flat support plate 50 on the back side thereof via a bonding layer (not shown) made of an adhesive material or the like, and the support plate 50 maintains its flatness. . However, the present invention is not limited thereto, and the reflective screen 10 may be supported by a frame member (not shown) or the like and maintain its flatness.
The reflective screen 10 has a large screen (display area) such as a diagonal of 80 inches or 100 inches. In the reflective screen 10 of the present embodiment, for example, the screen size is a diagonal size of 80 inches (1771 × 996 mm).

FIG. 2 is a diagram illustrating the layer configuration of the reflective screen 10 of the present embodiment.
In FIG. 2, it passes through the point A (see FIGS. 1A and 1B) which is the geometric center of the observation screen (display area) of the reflection screen 10, is parallel to the vertical direction of the screen, and is on the screen surface. A part of a cross section orthogonal (parallel to the thickness direction) is shown enlarged.
The reflective screen 10 includes a surface layer 15, a base material layer 14, a lens layer 13, a reflective layer 12, a light absorption layer 11, and the like in order from the image source side (observer O side).

The base material layer 14 is a sheet-like member serving as a base material for forming the lens layer 13. A surface layer 15 is integrally formed on the image source side (observer side) of the base material layer 14, and a lens layer 13 is integrally formed on the back side (back side).
The base material layer 14 includes a light diffusion layer 141 and a colored layer 142. In the base material layer 14 of the present embodiment, the light diffusion layer 141 and the colored layer 142 are integrally laminated. As shown in FIG. 2, the light diffusion layer 141 is the back side, and the colored layer 142 is the image source. Located on the side.
The base material layer 14 is not limited to the above-described example. For example, the light diffusion layer 141 may be located on the video source side, and the coloring layer 142 may be located on the back side. Further, the base material layer 14 may be a single layer containing both a diffusing material and a colorant such as a pigment or a dye, or may be a light diffusing layer 141 alone, or a transparent or substantially transparent resin. The light diffusion layer 141 and the colored layer 142 may be stacked on the image source side or the like.

The light diffusion layer 141 is a layer that contains a light transmissive resin as a base material and contains a light diffusing material. The light diffusion layer 141 has a function of widening the viewing angle and improving the in-plane uniformity of brightness.
Examples of the resin used as the base material of the light diffusion layer 141 include PET (polyethylene terephthalate) resin, PC (polycarbonate) resin, MS (methyl methacrylate / styrene) resin, MBS (methyl methacrylate / butadiene / styrene) resin, and acrylic resin. Resin, TAC (triacetyl cellulose) resin, PEN (polyethylene naphthalate) resin, or the like can be used. The light diffusion layer 141 has a thickness of 100 to 200 μm. Further, as the diffusing material, acrylic resin, epoxy resin, silicon-based resin particles, inorganic particles, and the like, and those having an average particle diameter of about 1 to 50 μm can be used.

The colored layer 142 is a layer colored with a dye or pigment such as gray or black to obtain a predetermined transmittance. In the present embodiment, the colored layer 142 is located on the image source side (observer side) of the light diffusion layer 141.
The colored layer 142 has a function of improving the contrast of the image by absorbing unnecessary external light such as illumination light incident on the reflective screen 10 and reducing the black luminance of the displayed image.
For example, the colored layer 142 has a thickness of 30 to 3000 μm and is formed of a PET resin containing a dye or a pigment, a PC resin, an MS resin, an MBS resin, an acrylic resin, a TAC resin, a PEN resin, or the like.
The base material layer 14 of the present embodiment is integrally formed by coextrusion of the light diffusion layer 141 and the colored layer 142.

FIG. 3 is a diagram illustrating the lens layer 13 of the present embodiment. FIG. 3A shows a state where the lens layer 13 is observed from the front side on the back side, and the reflection layer 12 and the light absorption layer 11 are omitted for easy understanding. FIG. 3B shows an enlarged part of the cross section shown in FIG.
The lens layer 13 is a light-transmitting layer provided on the back side of the base material layer 14, and a plurality of unit lenses 131 are arranged concentrically around the point C as shown in FIG. It has a circular Fresnel lens shape on its back side. In the circular Fresnel lens formed by arranging the unit lenses 131, the point C, which is the optical center (Fresnel center), is outside the area of the screen (display area) of the reflective screen 10, and Located below.
In the present embodiment, the lens layer 13 will be described with an example having a circular Fresnel lens shape, but may have a linear Fresnel lens shape.

2 and 3B, the unit lens 131 is parallel to the direction orthogonal to the screen surface (thickness direction of the reflective screen 10) and is a cross section in a cross section parallel to the arrangement direction of the unit lenses 131. The shape is a substantially triangular shape.
The unit lens 131 is convex on the back side, and includes a lens surface 132 and a non-lens surface 133 that faces the lens surface 132.
In the use state of the reflective screen 10, the unit lens 131 has the lens surface 132 positioned above the non-lens surface 133 in the vertical direction with the vertex t interposed therebetween.

In the unit lens 131, as shown in FIG. 3B, the angle formed between the lens surface 132 and the surface parallel to the screen surface is α, and the angle formed between the non-lens surface 133 and the surface parallel to the screen surface is β (β> α).
The arrangement pitch of the unit lenses 131 is P, and the lens height of the unit lenses 131 (the dimension from the apex t in the thickness direction of the screen to the point v that is the valley bottom between the unit lenses 131) is h.
In order to facilitate understanding, in FIG. 2 and the like, the arrangement pitch P and the angles α and β of the unit lenses 131 are shown to be constant in the arrangement direction of the unit lenses 131. However, the unit lenses 131 of the present embodiment actually have a constant arrangement pitch P and the like, but the angle α gradually increases as the distance from the point C that becomes the Fresnel center in the arrangement direction of the unit lenses 131 increases.

However, the present invention is not limited to this, and the angle α or the like may be constant, or the arrangement pitch P may gradually change along the arrangement direction of the unit lenses 131, and the pixel of the video source LS that projects the video light. It can be appropriately changed according to the size of (pixel), the projection angle of the image source LS (the incident angle of image light on the screen surface of the reflection screen 10), the screen size of the reflection screen 10, the refractive index of each layer, and the like. .
The lens layer 13 is formed of an ultraviolet curable resin such as urethane acrylate or epoxy acrylate. The lens layer 13 may be formed of another ionizing radiation curable resin such as an electron beam curable resin.

The reflection layer 12 is a layer having an action of reflecting light. The reflective layer 12 is formed on at least the lens surface 132.
As shown in FIGS. 2 and 3B, the reflective layer 12 of the present embodiment is formed on the lens surface 132, but not on the non-lens surface 133.
The reflective layer 12 can be formed on the lens surface 132 by evaporating or sputtering a metal such as aluminum, silver, or nickel.

The light absorption layer 11 is provided on the back side of the lens layer 13 and the reflection layer 12 and has a function of absorbing light. The light absorption layer 11 of the present embodiment covers the reflection layer 12 and the non-lens surface 133, and the light absorption layer 11 is formed on the non-lens surface 133.
The light-absorbing layer 11 is made of, for example, a thermosetting resin or an ultraviolet-curing resin containing a dark-colored paint such as black, a dark-colored pigment or dye such as black, and a bead having a light-absorbing action. Is applied to the back side (Fresnel lens shape side) of the lens layer 13 formed on the lens surface 132 and cured.

The surface layer 15 is a layer provided on the image source side (observer side) in the reflective screen 10. In the present embodiment, the surface layer 15 is on the image source side of the base material layer 14 and is provided at a position closest to the image source side.
The surface layer 15 can be provided with one or a plurality of necessary functions such as an antireflection function, an antiglare function, an ultraviolet absorption function, an antifouling function, an antistatic function, a hard coat function, and a touch panel function. .
The surface layer 15 of the present embodiment is formed of an ionizing radiation curable resin or the like having a hard coat function, has a film thickness of about 10 to 100 μm, has a fine uneven shape (mat shape) on the surface, and prevents Has dazzling function and hard coat function.
The surface layer 15 is a layer separate from the base material layer 14 and may be joined to the base material layer 14 with an adhesive material (not shown) or the like. It is good also as a form directly formed by apply | coating resin etc. which have a function.

Returning to FIG. 2, the state of the image light and the external light incident on the reflection screen 10 of the present embodiment will be described. In order to facilitate understanding, the refractive index of the surface layer 15, the colored layer 142, the light diffusion layer 141, and the lens layer 13 is assumed to be equal, and the light diffusion action of the light diffusion layer 141 with respect to the image light L1 and the external light G1, G2. Etc. are omitted.
As shown in FIG. 2, most of the image light L <b> 1 projected from the image source LS enters from below the reflection screen 10, passes through the surface layer 15 and the base material layer 14, and unit lens 131 of the lens layer 13. Incident to
Then, the image light L1 enters the lens surface 132, is reflected by the reflective layer 12, and exits from the reflective screen 10 toward the observer O side. The angle β (see FIG. 3B) is larger than the incident angle of the image light L1 at each point in the vertical direction of the screen of the reflection screen 10 when the image light L1 is projected from below the reflection screen 10. The image light L1 does not directly enter the non-lens surface 133, and the non-lens surface 133 does not affect the reflection of the image light L1.

On the other hand, unnecessary external lights G1 and G2 such as illumination light are incident mainly from above the reflection screen 10 and transmitted through the surface layer 15 and the base material layer 14 as shown in FIG. Incident on 131.
A part of the external light G1 enters the non-lens surface 133 and is absorbed by the light absorption layer 11. Further, a part of the external light G2 is reflected by the lens surface 132 and mainly travels to the lower side of the reflective screen 10, so that it does not reach the observer O side directly. Significantly less than the image light L1. Therefore, the reflective screen 10 can suppress a decrease in the contrast of the image due to the external lights G1 and G2.
Therefore, according to the reflective screen 10 of this embodiment, a bright and good image can be displayed even in a bright room environment.

Here, the manufacturing method of this reflective screen is demonstrated.
FIG. 4 is a diagram illustrating a method for manufacturing the reflective screen 10 of the present embodiment. FIG. 4 schematically shows a cross section passing through the point A, which is the center of the reflective screen 10, and parallel to the direction in which the unit lenses 131 are arranged and perpendicular to the screen surface (the thickness direction of the screen). ing. In FIG. 4, for ease of understanding, the base material layer 14 is shown as a single layer, but in actuality, it has a two-layer structure in which the light diffusion layer 141 and the colored layer 142 are integrally laminated.
First, as shown in FIG. 4A, a base material layer 14 is prepared. As described above, the base material layer 14 is formed by coextruding an MBS resin containing a diffusing material and an MBS resin containing a coloring material at a predetermined thickness.
The light diffusion layer 141 of this embodiment is a 150 μm thick layer of MBS resin containing acrylic resin particles having an average particle diameter of 10 μm as a diffusing material, and the colored layer 142 is an MBS resin containing a black pigment. The base material layer 14 uses a sheet-like member obtained by co-extrusion molding. In the present embodiment, it is assumed that the base material layer 14 has a web shape.

Next, as shown in FIG. 4B, urethane acrylate or the like is applied to the surface of the base material layer 14 on the image source side (in this embodiment, the surface on the colored layer 142 side) with a film thickness of about 30 μm. Then, a fine uneven shape (matte shape) is cured by transferring it to the surface of the resin film, and the surface layer 15 having the fine uneven shape is formed on the surface.
Next, as shown in FIG.4 (c), the masking material M is bonded on this surface layer 15 so that peeling is possible. The masking material M is a transparent or substantially transparent sheet-like member, and has a function of preventing the surface layer 15 from being stained or damaged in the subsequent manufacturing process. Moreover, it is preferable that this masking material M has the tolerance with respect to the etching liquid mentioned later.
Next, the surface layer 15 and the base material layer 14 to which the masking material M is bonded are cut into a predetermined size to form a single wafer.

Then, as shown in FIG. 4D, the lens layer 13 is formed on one surface of the base material layer 14 on one surface (the surface on the light diffusion layer 141 side in this embodiment) on one surface of the base material layer 14 by an ultraviolet molding method or the like. (Lens layer forming step).
The lens layer 13 is filled with an acrylic ultraviolet curable resin on the surface opposite to the surface on which the surface layer 15 of the base material layer 14 is laminated (in this embodiment, the surface on the light diffusion layer 141 side). The circular Fresnel lens shape is formed by pressing against a forming mold, irradiating and curing with ultraviolet rays, and then releasing from the forming mold. The method for forming the lens layer 13 may be selected as appropriate, and is not limited to this.

Next, the reflective layer 12A is formed on the surface of the lens layer 13 on the Fresnel lens shape side (reflective layer forming step).
As shown in FIG. 4E, the reflective layer 12A is formed by depositing aluminum on the lens surface 132 and the non-lens surface 133 of the lens layer 13 by vacuum deposition. At this time, the vapor deposition source is arranged at a predetermined distance from the lens layer 13 on the side facing the surface having the Fresnel lens shape of the lens layer 13, and the evaporated vapor deposition material is the lens surface 132 of the unit lens 131. It is preferable that the lens layer 13 is disposed so as to hit the surface of the lens layer 13 from the side. By arranging the vapor deposition source as described above, the vapor deposition direction is from the lens surface 132 side, and the vapor deposition material evaporated on the non-lens surface 133 side is difficult to hit. Therefore, as shown in FIG. 4F, the reflective layer 12A is formed on the lens surface 132 with a thickness greater than that necessary for reflection, but on the non-lens surface 133, the lens surface 132 is formed. The thickness is formed thinner than that.
It should be noted that the number and arrangement of the evaporation sources are the size of the screen of the reflective screen 10, the arrangement pitch P of the unit lenses 131, and whether the Fresnel lens shape formed on the lens layer 13 is a circular Fresnel lens shape. Depending on whether it is a shape or the like, it can be appropriately selected and set.

Next, as shown in FIG. 4G, the laminated body S in which the reflective layer 12A, the lens layer 13, the base material layer 14, the surface layer 15, and the masking material M are integrally laminated is set to a predetermined temperature. Etching (wet etching) is performed by immersing in the etching solution E for a predetermined time. Thereby, the reflective layer 12A formed on the non-lens surface 133 is corroded and removed (reflective layer removing step).
In the present embodiment, an example of using a dipping method in which the stacked body S is immersed in the etchant E is shown as an etching method. However, the present invention is not limited to this. For example, the etchant is sprayed on the surface of the reflective layer 12A by spraying. A spraying method may be used.
In the present embodiment, the etching solution E is preferably acidic, and more preferably a mixed solution of sulfuric acid and hydrochloric acid. The etchant E may be an aqueous solution of ferric chloride. The etchant E may be alkaline depending on the resin characteristics of the lens layer 13, the base material layer 14, and the surface layer 15. Further, depending on the characteristics of the reflective layer 12A, the lens layer 13, etc., the reflective layer on the non-lens surface 133 may be removed by dry etching.

Since the reflective layer 12A on the lens surface 132 is not protected by a resist material or the like, the surface of the reflective layer 12A on the lens surface 132 is also corroded by etching. However, since it is formed with a thickness greater than that necessary for reflection by vapor deposition, even when the reflective layer 12A of the non-lens surface 133 is removed by etching, the lens surface 132 has a sufficient thickness. The reflective layer 12A (about 0.1 μm) remains.
Note that the surface and the like on the surface layer 15 side are protected by the masking material, so that they are not melted by the etching solution E.
Next, the surface of the laminate S is washed to remove the etching solution E. As shown in FIG. 4H, the reflective layer 12 is formed on the lens surface 132, and the reflective layer 12A on the non-lens surface 133 is removed.

Next, as shown in FIG. 4I, ink containing a black pigment that is a light absorbing material is applied onto the lens layer 13 by screen printing or the like and cured to form the light absorbing layer 11. In addition, the method of apply | coating a light absorption material is not restricted to said screen printing, For example, methods, such as application | coating by a gravure reverse coat, an inkjet system, a die coat system, and a flow coat system, can be used.
The light absorption layer 11 of this embodiment is formed by applying black ink by screen printing or the like, and has a thickness of about 60 μm.

Next, the masking material M is peeled off from the surface layer 15, and the reflective screen 10 is completed through a subsequent process such as a further cutting process.
In addition, in this embodiment, although the base material layer 14 was web shape and it bonded and demonstrated the example which cuts the base material layer 14 and the surface layer 15 in sheet form after bonding the masking material M, to this, Not limited to this, a sheet-like base material layer 14 cut in advance may be used. In the present embodiment, the surface layer 15 is formed on one side of the base material layer 14 in advance, and then the lens layer 13 is formed. However, the present invention is not limited thereto. For example, after the lens layer 13 is formed, The surface layer 15 may be formed.
The bonding of the masking material M may be omitted as appropriate according to the characteristics of the surface layer 15 and the like.

With the manufacturing method as described above, the reflective layer 12A on the non-lens surface 133 that does not contribute to the reflection of the image light can be easily removed. Further, since a protective material (mask material, resist material, etc.) for protecting the reflective layer 12A on the lens surface 132 is not necessary, the reflective layer 12A on the non-lens surface 133 can be removed easily and at low cost. .
From the above, according to this embodiment, it is possible to easily manufacture a reflective screen that can display a good image with a bright and high contrast. In addition, according to the present embodiment, it is not necessary to protect the reflective layer 12A on the lens surface 132 with a resist material or the like, so that the manufacturing cost can be greatly reduced and a reflective screen capable of displaying a good image can be provided at a low cost. it can.

FIG. 5 is a diagram illustrating a reflective layer 22 according to another embodiment. Fig.5 (a) shows the reflection layer 22 of another embodiment, and FIG.5 (b) is a figure which shows typically the lens layer after the reflection layer formation process in this another embodiment. 5A corresponds to the cross section shown in FIG. 3B, and only the lens layer 13, the reflection layer 22, and the light absorption layer 11 are shown.
As shown in FIG. 5A, the reflective layer 22 is formed only in the reflective region 132a where the image light on the lens surface 132 reaches, and the non-reflective region 132b on the lens surface 132 where the image light does not reach. The non-lens surface 133 may not be formed.

  In the above-described reflective layer forming step, vapor deposition is performed from the lens surface 132 side so that the vapor deposition material hits the lens surface 132 side. The nearby non-reflective region 132b can be formed to be thinner than the reflective region 132a. At this time, the thickness of the reflective layer 22A formed on the non-lens surface 133 is also thinner than the reflective layer 22A formed on the reflective region 132a. Therefore, in the above-described reflection layer removing step, the non-reflective region 132b and the non-lens surface 133 are formed by etching by adjusting the time during which the stacked body S is immersed in the etchant E, the temperature and concentration of the etchant E, and the like. The reflective layer 22A can be removed to easily form the reflective layer 22 only in the reflective region 132a.

  With such a reflective layer 22, a part of unnecessary external light such as illumination light enters the non-reflective region 132 b of the lens surface 132 and is absorbed by the light absorbing layer 11, thereby further improving the contrast. Can be expected.

(Deformation)
The present invention is not limited to the embodiment described above, and various modifications and changes are possible, and these are also within the scope of the present invention.
(1) In the present embodiment, an example in which the reflection layer 12A of the non-lens surface 133 is completely removed has been shown. However, the present invention is not limited to this, and at least one of the layers has a thickness that does not contribute to light reflection. It may remain in the part. If the reflective layer has a thickness that does not contribute to the reflection of light, the external light incident on the non-lens surface 133 is incident on the light absorption layer 11 as it is and is absorbed. High image quality can be displayed.

(2) In this embodiment, the lens layer 13 is made of an ultraviolet curable resin, and is integrally formed on the back surface (the light diffusion layer 141 side) of the base material layer 14 by the ultraviolet molding method. However, the present invention is not limited thereto, and the lens layer may be formed by, for example, a thermoplastic resin or the like by an extrusion molding method or an injection molding method.
In the case of the extrusion molding method, extrusion molding may be performed in a state where the lens layer 13 and the base material layer 14 are laminated integrally. By adopting such a form, mass production is further facilitated and can be provided at low cost.

(3) In the present embodiment, the example in which the surface layer 15 is a single layer is shown. However, the surface layer 15 is not limited thereto, and has, for example, functions such as an antireflection function, an ultraviolet absorption function, an antifouling function, and an antistatic function. It is good also as a form which laminates | stacks a layer further.

(4) In the present embodiment, the reflective screen 10 is joined to the support plate 50 provided on the back side thereof via an adhesive material layer (not shown) and the like, and an example of a substantially flat plate shape is shown. Not limited to this, for example, the support plate 50 may not be provided, and the reflective screen 10 may be bonded to the wall surface or the like via an adhesive layer or the like, or may be fixed to the wall surface with the support plate 50 bonded to the back surface. It is good also as a form etc. which are hung on a wall surface by support members, such as a hook. Furthermore, in order to maintain the flatness of the screen of the reflective screen 10, a highly rigid substrate layer made of glass or resin may be provided.

(5) In the present embodiment, the reflective screen 10 has an example of a substantially flat shape when in use and not in use. However, the present invention is not limited to this, and the reflective screen 10 can be wound up and stored when not in use. Good. In such a form, the support plate 50 or the like is not provided, and the back side of the reflective screen 10 is covered with a cloth or resin light-shielding curtain that hardly transmits light, a protective layer that improves scratch resistance, or the like. It is good.

(6) In the present embodiment, the unit lens 131 has an example in which the lens surface 132 and the non-lens surface 133 are linear in the cross section shown in FIG. 2 and the like. Part of the lens surface 132 and the non-lens surface 133 may be curved.
In the present embodiment, the lens surface 132 and the non-lens surface 133 of the unit lens 131 are both single surfaces. However, the present invention is not limited to this. For example, at least one surface is a plurality of surfaces. It is good also as a form comprised from.

(7) In the present embodiment, the video source LS is located below the reflecting screen 10 in the vertical direction, and the image light L is projected obliquely from below the reflecting screen 10. However, the present invention is not limited thereto. For example, the video source LS may be positioned above the reflective screen 10 in the vertical direction, and the video light L may be projected obliquely from above the reflective screen 10. At this time, the reflection screen 10 is reversed in the vertical direction of the lens layer 13 shown in FIG. 2 and the like, and the point C which is the optical center (Fresnel center) of the circular Fresnel lens is positioned above the reflection screen 10. That's fine.

  In addition, although this embodiment and modification can also be used in combination as appropriate, detailed description is abbreviate | omitted. Further, the present invention is not limited to the embodiment described above.

DESCRIPTION OF SYMBOLS 1 Video display system 10 Reflective screen 11 Light absorption layer 12 Reflective layer 13 Lens layer 131 Unit lens 132 Lens surface 133 Non-lens surface 14 Base material layer 141 Light diffusion layer 142 Colored layer 15 Surface layer

Claims (5)

A lens layer having a lens surface and a non-lens surface and having a Fresnel lens shape in which a plurality of unit lenses convex on the back side are arranged; and a reflective layer formed at least on a part of the lens surface; A method of manufacturing a reflective screen that reflects image light projected from an image source and displays the image light in an observable manner,
A lens layer forming step of forming the lens layer having a Fresnel lens shape in which a plurality of the unit lenses are arranged on one surface;
A reflective layer forming step of forming a reflective layer on the lens surface and the non-lens surface;
A reflective layer removing step of removing at least the reflective layer formed on the non-lens surface;
Providing
A manufacturing method of a reflective screen characterized by the above. In the manufacturing method of the reflective screen of Claim 1,
In the reflective layer removing step, at least the reflective layer formed on the non-lens surface is removed by etching,
A manufacturing method of a reflective screen characterized by the above. In the manufacturing method of the reflective screen of Claim 2,
Etching used in the reflective layer removing step is wet etching,
A manufacturing method of a reflective screen characterized by the above. In the manufacturing method of the reflective screen of any one of Claim 1- Claim 3,
In the reflective layer forming step, the thickness of the reflective layer formed on the non-lens surface is smaller than the thickness of the reflective layer formed on the lens surface;
A manufacturing method of a reflective screen characterized by the above. In the manufacturing method of the reflective screen of any one of Claim 1- Claim 4,
In the reflective layer removal step, removing the reflective layer formed on the non-lens surface and the reflective layer formed on the non-reflective region that does not contribute to the reflection of the image light on the lens surface;
A manufacturing method of a reflective screen characterized by the above.

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